Advanced modeling and computation at Boston Valley Terra Cotta

View website
Year
2015
Contribution
3D
Design
Intro
Boston Valley is the nation's leading manufacturer of architectural terra cotta. The company has become known for its expertise in integrating digital tools with the ancient art of designing stunning terra cotta, an ideal workflow for preservation projects. Using point clouds, photogrammetry, and advanced manufacturing, we replaced and renewed gorgeous façades.

Why did we care?

When I joined Boston Valley in 2015, the company was in the midst of a major transformation of both its design and prouduction pipelines. By leveraging emergent technologies, the company could gather site data (photogrammetry and point clouds), produce 3D models (Rhino, Grasshopper, and Python), and build terra cotta blocks (CNC molding and foam cutting) more effectively and more accurately. The company found a willing partner in the University at Buffalo, as advanced computational design was a core part of our architectural curriculum.

My role included using profile measurement tools and laser cutters to accurately measure and model complex terra cotta samples.


In addition, I also:


(1) built intricate, watertight 3D models using Rhino and Grasshopper,

(2) wrote and edited scripts in Python to expedite manufacturing processes and

(3) designed façade assemblies to propose structural elements.

This is the dome of the Alberta Legislative Building in Edmonton.
Example of a field survey. Photogrammetry and scanning are used to label and measure the stones.
We recreate the assembly and make a more detailed scan.
Photogrammetry scan vs 3D model
Scans alongside 3D models in Rhino
Example of an assembly in Rhino
This is a different project, but you can see how the scan data is combined with 3D modeling to replicate the assembly.
These 3D models are sent to the CNC router. Molds are made in plaster or foam.
The molds are combined with the work of a sculpture to make a perfect replica.
Here we see the original stone with our assembly. Notice the wood profiles to help guide the sculpting.
No items found.

And the tl;dr

Projects at Boston Valley were detailed, nuanced, and fascinating. Here are a few things I'm proud of about my time there.

  1. I begged to rotate between all of the departments. This helped me to understand the entire workflow – from when samples are delivered to when the final blocks are shipped out. Not only was I picking up new Rhino and Python skills everyday, I also learned how to make molds, do advanced CNC work, work a kiln, and pack finished blocks for safe delivery. It is an honor to learn alongside tradespeople and see them at work.
  2. I got swole. My car was an old beater that drained my bank account. So I biked from downtown Buffalo to BVCT at least three times a week. That's 50 miles a day. And then, once I got to work, I was carrying around 60lb stones all day! I was a beast. I channeled the physical strength to complete a century in the Ride for Roswell, raising money for cancer research.
  3. I learned to back up my work. When a huge layoff hit our department, I was let go. Sadly, there was no time to document the gorgeous work I'd helped create. Now, I rigorously document as much as I can. While we're on the topic, all images on this page are from Boston Valley. They're projects I worked on, but I do not own the images.
Plaster molds with terra cotta inside.
Molds have been removed, and the blocks are drying.
Checking the assembly for accuracy and completeness.
Accounting for everything.
A complete, finished assembly with steel anchors. Nearly ready for shipment.
Blocks are then carefully packaged and shipped.
No items found.

Projects or questions?

Let's do the thing.